Thermoformed flexible package with enlarged integral removable tab at distal end of dispensing tube

ABSTRACT

The removable sealed closure portion of the dispensing tube of a flexible thermoformed dispensing package for flowable materials is provided with an enlarged safety tab that can be integrally formed with, or separately secured to the sealed closure portion, the enlarged safety tab being dimensioned and configured to avoid inadvertent ingestion by a human or small pet when the tab is removed to open the dispensing tube in preparation for dispensing the product. In addition to functioning as a “flag”, the surfaces of which can be printed with source-identifying indicia and other consumer information, the enlarged safety tab formed in an open-ended folded configuration and provided with interior fields of repositionable pressure sensitive adhesive, serves as a protective cover and seal when removed and placed over the open end of the dispensing tube to preserve any remaining material in the container portion of the package.

FIELD OF THE INVENTION

This disclosure relates to the construction and functioning of highly flexible thermoformed dispensing packages for flowable materials formed with integral dispensing tubes.

BACKGROUND OF THE INVENTION

A feature that is common to highly flexible dispensing packages of the prior art that are dimensioned and configured with a container portion containing a flowable material in a transport/storage configuration and for dispensing the flowable material in the dispensing configuration, is an integral dispensing tube having one end in fluid communication with the container portion and a second or distal sealed end that is closed in the transport/storage configuration and that defines an opening in the dispensing configuration such that the material contained in the package can flow from the container through the integral dispensing tube and exit the package via the opening.

An embodiment of a prior art flexible dispensing package (10) produced as described in U.S. Pat. No. 9,815,606 is schematically illustrated in FIG. 1A. The container portion (12) is shown with flowable contents (18) supported on the extended bottom wall (14) to provide a stand-up configuration for the highly flexible package. The integral dispensing tube (14) projects from top wall or seam (16) and the dispensing channel is opened by removing the sealed end (22) of the tube (14) generally along an indicated tear line (26) between notches (24), or another easy-opening feature. Once removed to open the package for dispensing of the contents, the relatively small piece of soft flexible sealed plastic material (22) used in the construction of the package becomes waste that must be disposed of by the user.

In the case of the type of prior art flexible container (30) illustratively shown in FIG. 1B, after opening for dispensing of the contents, the twist-off cap (36) becomes a waste element that must also be disposed of by the user. Thus, when opened for use, both types of prior art packages described will have been separated into two parts, which in the case of the highly flexible package of FIG. 1A, are the principal container portion (12) and open dispensing tube (14) ready for dispensing and the residual sealed portion (12) adjacent the tear notch (24), and in the package of FIG. 1B, the twist-off cap (36) and the container portion (32).

In both cases, the separated closure portion constitutes a potential danger to a small child or infant who may put the closure in her mouth with the risk of swallowing and choking on it. It would therefore be desirable to provide a highly flexible dispensing package having a dispensing tube in which the problem of the potential hazard posed by the separated sealed closure portion is eliminated or minimized.

SUMMARY OF THE INVENTION

These problems are resolved and additional benefits are realized by providing the removable sealed distal end of the dispensing tube with an laterally extending enlarged safety tab that is dimensioned and configured to discourage its placement in the mouth by an infant or small child and, even in that event, render it not easily swallowed by infants, small children or pets. In addition to the obvious safety advantage, the enlarged safety tab can be configured as a “flag,”, “banner” or other shape associated with the product contained in the package. The enlarged safety tab also provides additional surface area for branding and/or printed promotional matter.

In one especially preferred embodiment, when it is foreseeable that the contents of the container will not be consumed or dispensed following removal of the scaled end of the dispensing tube, the enlarged safety tab is so configured and dimensioned that following its removal it can be placed over the open end of the dispensing tube, thereby serving as a “cap” or temporary closure between uses. The cap can serve to maintain the cleanliness of the open end and also to minimize the inadvertent discharge of the contents remaining in the container portion.

Since the enlarged safety tab is an integral extension of the existing highly flexible packaging material, it is advantageously formed on the package forming machine as will explained in more detail below. The size, shape and prospective use of the enlarged safety tab is determined by the packaging designer for a particular product and/or market, and is therefore infinitely variable.

In accordance with methods known in the prior art, the construction of the package can be from two sheets of flexible material that are scaled together, or a single sheet that is folded at the perimeter in order to construct the container and dispensing tube. In this case, the expanded tab can be formed by sealing the flexible packaging material from both sides together or extending the material from one side. The enlarged safety tab can be sized to meet the specifications of the customer, with the understanding that the mass production of flexible dispensing packages with larger tabs will be somewhat costlier with respect to the materials of construction and the manufacturing process employed.

In the drawings that follow and in their associated written description, the flexible dispensing package and integral dispensing tube are illustrated using a two-dimensional representation in the interest of clarity. However, it will be understood from the description of the flexible dispensing packages of the prior art provided above, that once filled, the container portions of the dispensing packages assume a variety of three-dimensional shapes. In certain preferred embodiments of the present invention, the flexible dispensing package is dimensioned and configured to assume a stand-up orientation with the dispensing tube projecting generally vertically from the top of the container portion of the package. A specific version of this particular configuration is depicted in FIG. 1A. Other embodiments of highly flexible packages of the prior art for which the present invention is imminently suited and conveniently adapted for use are described in U.S. Pat. Nos. 10,059,498, 4,815,606 and 9,187,225, the disclosures of which are hereby incorporated by reference, in their entireties, to the extent permitted by the custom and practice of any jurisdiction in which this application is filed.

It will be understood from the representational schematic illustrations comprising the majority of the attached figures that the present invention broadly comprehends a highly flexible thermoformed dispensing package having an integral dispensing tube, the distal end of which is formed with an integral enlarged safety tab, which tab defines a generally planar surface that projects laterally from one or both sides of the longitudinal axis of the dispensing tube. In in this regard, the representational drawings of the flexible dispensing package accurately portray the generally planar configuration of the enlarged safety tab and its position at the sealed terminus of the hollow dispensing tube at the time of manufacture of the package.

It will be understood that the flexible dispensing package is produced from flexible sheets or webs of highly flexible polymeric materials that are readily thermoformed. Suitable materials include polyethylene and polypropylene, or a blend, such as polyethylene and ethylene vinyl acetate. When two sheets or webs are used, they can be the same or different the materials.

In an embodiment, the enlarged safety tab is reinforced to reduce its flexible characteristics. The reinforcement can be accomplished by securing a separate planar member having greater rigidity, such as a thin semi-rigid polymer sheet, a piece of paperboard placed between the portions of the film from which the package is made, or the like. The enlarged safety tab can also be rendered less flexible by the application of a liquid polymer that is sprayed, or applied by known mechanical means to all or predetermined portions of the exterior surface of the package or of the separate reinforcing material. It will be understood that if either a separate sheet of less flexible material or a chemical coating that dries and cures to a semi-rigid form is selected, the resilience of the enlarged safety tab is to be retained and brittleness and sharp edges are to be avoided in the finished product.

In the embodiment where a separate sheet or section of a less flexible material is secured to the enlarged safety tab, it can advantageously be provided with text, illustrations, designs and other indicia that are intended to attract a consumer's attention and/or provide useful information relevant to the material contained in the flexible dispensing package of which it is a part.

Whatever method is chosen for stiffening or reinforcing the enlarged safety tab, the effect will be to provide a removable portion that has sufficient dimensional stability to render it difficult, if not impossible for a small child or infant to place in her mouth, let alone swallow, thereby avoiding the potential hazard presented the small portion of the sealed dispensing tube of the prior art that is removed in preparation for use.

In embodiments of the invention which are described in more detail below, opposing surfaces of the enlarged safety tab employ one or more pressure sensitive (PS) adhesives to form resealable closures for the open end of the dispensing tube to retain any remaining flowable material. One such adhesive is known as “repositionable”, that is, the surface(s) having a coating of the adhesive can be pressed for adhesion, separated and then rejoined by application of manual pressure. A well known example of the use of this type of PS adhesive is that used on the popular Post-It™ notes.

Also suitable for use in the invention are adhesives commonly known as “cohesives” which is a class of chemical adhesive compositions that only “recognizes” and adheres to itself. Once it is applied to a surface and cures, it is not apparent to the touch, i.e., there is no tack or sticky feel.

The conventional PS adhesive is most easily recognized in applications such as tape, i.e. duct tape, packaging and the like. Its bond strength (“tack”) can be adjusted according to the application, from weak to strong.

PS adhesives are generally applied to the substrate in a liquid form, including in a hot melt form, by any of several methods, including as a spray, and by roller application similar to a printing press cylinder. In some cases, PS adhesives are pre-applied to both sides of rolls of a film or tape and then the film is applied to the surface of the object and presents the second tacky surface for the intended purpose at the time of its use.

In accordance with the present invention, food grade PS adhesives are employed to create closures in a portion of the dispensing tube that extends from the container portion of the package after the initial opening. These embodiments are advantageously provided for use in those instances when the entire contents of the pouch are not consumed or dispensed and the user wishes to close the package and keep the balance for use or consumption at a later time. Embodiments of the present invention are further described that employ food grade PS adhesives.

As used in this application the terms “tear notch” and “weakened parting line” shall be understood to include other easy-opening configurations such as laser scores, weakened tear lines, and the like that are well known in the art, and which are provided to identify and facilitate removal of that portion of the package in preparation for dispensing of its contents.

Methods for mass production of thermoformed flexible dispensing containers having dispensing tubes with which the enlarged safety tabs of the present disclosure can be utilized are known in the art, and are described, for example, in U.S. Pat. Nos. 8,381,941, 9,187,225, 9,758,284 and 10,059,498, among others, the disclosures of which are incorporated herein by reference, to the extent permitted by examining authorities in which this application is filed.

As will be understood from the above, the present invention broadly comprehends providing the dispensing tube of a thermoformed flexible package with an enlarged safety tab that is integral with the tear off portion that seals the end of the dispensing tube prior to use, and once removed, is not subject to inadvertent ingestion by a human or house pet.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention and its various embodiments will be described in further detail below and with reference to the attached drawings in which the same or similar elements are referred to by the same number, and in which:

FIG. 1A is an embodiment of thermoformed highly flexible dispensing package of the prior art having an integral dispensing tube with a manually removable integral sealed portion at its free end;

FIG. 1B is an embodiment of a dispensing package of the prior art having a container portion formed from a flexible film that is provided with a molded plastic fitment and a separate screw cap closure;

FIG. 2 is a simplified schematic illustration of an embodiment of a highly flexible dispensing package that includes a generally rectilinear enlarged safety tab in accordance with the present invention;

FIG. 3 is a simplified schematic illustration of a highly flexible dispensing package in accordance with the present invention that includes a curvilinear enlarged safety tab configured to extend laterally over the container portion from the integral dispensing tube;

FIG. 4 is a schematic illustration of a flexible dispensing package similar that of FIG. 3 in which a curvilinear enlarged safety tab extends laterally from both sides of the dispensing tube;

FIG. 5 is a simplified schematic illustration of an embodiment similar to that of FIG. 3 in which the separated enlarged safety tab is placed over the open end of the dispensing tube;

FIGS. 6A, 6B and 6C are a sequential series of simplified schematic illustrations of an embodiment in accordance with the present invention of a separated enlarged safety tab with fields of adhesive positioned to provide a removable closure or cover for the open end of the dispensing tube.

FIG. 7 is a simplified schematic illustration of an embodiment in accordance with the present invention of an enlarged safety tab with fields of cohesive adapted to form a removable closure or cover for the open end of the dispensing tube;

FIGS. 8A and 8B are simplified sequential schematic illustrations of a flexible dispensing package in accordance with the present invention illustrating a field of cohesive on the exterior surface of the dispensing tube to securely close the open end of the dispensing tube along a prescribed transverse score or fold line;

FIG. 9 is a simplified schematic illustration similar to FIG. 8A in which the prescribed fold line is disposed diagonally at an acute angle to the longitudinal axis of the dispensing tube;

FIGS. 10A, 10B and 10C are a sequential series of simplified schematic illustrations of a flexible stand-up dispensing package of the same general configuration shown in FIG. 1A, in which FIG. 10A is a partly exploded view to show the positioning in the dispensing channel of a field of repositionable PS adhesive that seals the channel after removal of the sealed end portion and its displacement in FIG. 10C to resume dispensing of the flowable material in the container portion; and

FIG. 11 is a simplified schematic illustration of an embodiment in accordance with the invention in which the dispensing tube is provided with a resealable zipper closure and an enlarged safety tab.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 2 , an embodiment of the enlarged safety tab (230) at the terminus of the distal end of the dispensing tube (214) of a typical flexible dispensing package (200) is illustrated in which the enlarged safety tab extends laterally inward, i.e., in the direction that positions the extended body of the enlarged safety tab over the container portion (212) of the flexible package. As illustrated in FIG. 2 , the dispensing channel (220) is opened by removing the sealed portion (232) of the dispensing tube along the weakened parting line (226) extending between opposing notches (224) that are formed during the mass production of the flexible packages. In the embodiment illustrated, the sealed portion (232) projects from the lower edge of the enlarged safety tab (230). It will be understood that the weakened parting line can be formed as an extension of the bottom edge (236) of the enlarged safety tab (230) with a single notch as shown on the right side of the dispensing tube (214) below the sealed portion to thereby eliminate the projection.

FIG. 2 thus illustrates an embodiment of generally rectilinear enlarged safety tab that is dimensioned to be within the “footprint” or dimensional boundaries of the container portion and dispensing tube (212) of the original package (200). The dimensions of the enlarged safety tab can be increased proportionally and remain within the original footprint. As will be appreciated by one of ordinary skill in the art and explained in more detail below, this configuration will produce economies in both packaging material used and machine productivity.

Referring to FIG. 3 , the enlarged safety tab (330) as illustrated is of a partially circular or oval configuration that creates a different visual impression than the rectilinear element of FIG. 2 . FIG. 3 represents a hybrid configuration with a rounded flag that lies within the footprint. In all other respects, the elements and the series of reference numerals used in FIG. 3 and the figures that follow correspond to those described in connection with FIG. 2 .

A further representative embodiment is illustrated in FIG. 4 in which the sealed end portion (432) is formed within body or perimeter of the removable enlarged safety tab (430), thereby eliminating the projecting portion as shown in FIGS. 2 and 3 . Also note that FIG. 4 illustrates a rounded or oval shaped enlarged safety tab (430), e.g., a “balloon”, that extends beyond the footprint of the combined dispensing tube (414) and container portion (412) of the package. As noted above, this configuration will add to the cost of the mass production of the package (400) as compared to the packages (200 and 300) illustrated in FIGS. 2 and 3 .

In other embodiments, the enlarged safety tab can extend laterally outwardly, i.e., to a position away from the container portion of the package, or the enlarged safety tab can extend laterally in both directions from the longitudinal axis of the dispensing tube. The enlarged safety tab can also be extended vertically to a portion adjacent but separated from the dispensing tube (not shown).

For each of the representative embodiments of FIGS. 2, 3 and 4 , the enlarged safety tab can serve purposes other than as a deterrent to the ingestion of the part following its removal to open the package for use. For example, if the flexible dispensing package contains an industrial product, sick as a lubricating oil, a paint colorant or other chemical additive, the enlarged safety tab can serve as a quality and/or grade indicator using colors, large knit numerals and letters, and/or other indicia. The enlarged safety tab can also serve as a promotional printed piece carrying a coupon and/or informational copy including directions, ingredients and the like. It can also be used to comet information that is not directly related to the product. For example, it can, quite literally serve to illustrate flags, such as a series of flags of various countries of the world “waving” from the dispensing tube extending from a container of yogurt on the store shelf. The illustration can be printed on both sides of the tab so that its placement on the shelf is not limited to one orientation.

Covering the Open Dispensing Tube

FIG. 5 illustrates an enlarged safety tab (530) that is generally rectangular following its removal from the dispensing tube (not shown) along a weakened parting line (526), which is adjacent to upper left-hand corner. As shown in FIG. 5 the enlarged safety tab is sealed along the perimeter of three sides (540A, 540B, 540C). The fourth side is unsealed allow it to be opened as shown in FIG. 5 and placed over the opened free end of the dispensing tube (514), providing a cover or cap which some contents remain after the container portion (512) has been opened for use.

In further embodiments of the present invention, the distal portion of the dispensing tube, once opened for removal of the flowable contents in the container portion, is resealable by adhesives and/or a mechanical closure.

Referring now to the simplified schematic sequential series of FIGS. 6A, 6B and 6C, the use of an enlarged safety tab (630) as a temporary cap or closure for the open dispensing tube following its removal in order to retain a portion of the flowable material in the container portion (612) of opened package (600) will be illustrated. As shown in FIG. 6A, several fields of pressure sensitive (PS) adhesive (650, 652, 654) are applied at predetermined spaced-apart locations on the interior surface of separated enlarged safety tab (630), in order to position the open end of the dispensing tube (614) between the fields of adhesive. In FIG. 6B, the upper portion of the enlarged safety tab is shown partly folded down over the dispensing tube, and finally as shown in FIG. 6C, secured in position with the opposing fields of adhesive in contact thereby providing a temporary removable seal for the open end of the dispensing tube (614).

In the embodiment schematically illustrated in FIG. 7 , a plurality of fields of a cohesive (750, 752) are applied to one surface of the enlarged safety tab to provide a closure for the open end of the dispensing tube (714) following removal of the enlarged safety tab to open the dispensing channel. As illustrated, the lower edge of the enlarged safety tab includes the tear notch (724) and the weakened parting line (726). In order to releasably seal the dispensing tube (714) after an initial or subsequent use, the distal end of the open tube is positioned between the fields of cohesive (750, 752) and pressure is applied manually to join the cohesive material and thereby close the dispensing channel (720) and prevent passage of the flowable material from the container portion (12). Note that as illustrated, the fields (750, 752) are positioned inboard from the opposing edges of the enlarged safety tab (730) to permit the user to manually grasp the free ends and separate the temporarily bonded fields of cohesive, it will be understood that one or more additional fields of cohesive can optionally be applied to the enlarged safety tab (730) to further secure the opening where, e.g., the flowable material is a liquid of low viscosity. For example, a field of cohesive (754) is applied transversely along of proximate to the upper edge (738) of the enlarged safety tab (730) to effectively provide a closed cap for the dispensing tube channel (720).

FIG. 7 illustrates one example of the application of a liquid food grade PS cohesive in the form of parallel bands or fields on the surface of an enlarged safety tab configured as described above. These fields of adhesives can be applied during the manufacture of the flexible packaging material, or film, by methods similar to off-set printing. In this embodiment, the PS adhesive is applied in liquid form to the surface of the film much the same way as ink is applied to produce punted fields of text and/or images on the film.

The purpose of the adhesive fields of FIG. 7 is to create opposing matching zones of the food grade PS cohesive and as will be clear to one skilled in the art, the application of particular patterns or stripes is not necessary, and 100% coverage of the opposing surfaces with the PS cohesive can be provided if this process is more convenient, cost effective and/or efficient in the production of the flexible dispensing packages. The application of smaller opposing fields that consume less cohesive material is a lower cost alternative, as is any variation of the lay-down that comprises less than 100% coverage.

As was described above, the enlarged safety tab of FIG. 7 , being an extension of the free end of the dispensing tube above the tear notch becomes one piece along with the remainder of the dispensing tube after that piece is removed.

In an embodiment, the food grade PS adhesive is applied to the film on the package-forming machine as the film is unwound from the mill roll. In this method, a device similar to an on-line printing/coding apparatus is installed at a predetermined station on the forming machine and activated to apply the food grade PS adhesive as the sheet from the mill roll passes the station.

The adhesive can also take the pattern of a full laydown of the food grade PS cohesive covering the full surface of the inside of the enlarged safety tab, with the exception of the open area that will serve as the unsealed region into which the open dispensing tube will be inserted.

With reference to FIGS. 6 and 7 , one configuration for the positioning of the enlarged safety tab is illustrated using the PS adhesive. The enlarged safety tab can be positioned in various configurations, as long as the sealed enlarged safety tab covers the open end of the dispensing tube.

The use of a food grade PS cohesive is preferred so that the non apparent surface the adhesive, being fully exposed in its original form, e.g., as in FIG. 7 , does not interfere with the normal handling of the package during its full life cycle. This includes during placement of the individual filled packages in shipping cartons, during removal and placement of the packages on shelves for display in supermarkets or at other point of sale locations, and during handling consumers during storage and in preparation for use.

In the series of illustrations of FIGS. 8A, 9 and 10A, the enlarged safety tabs have been omitted in rho interests of clarity, and it will be understood that the EST would have been removed from the dispensing tubes of FIGS. 8B, 10B and 10C.

In an alternative embodiment of the resealable package depicted in FIGS. 8A and 8B, the food grade PS cohesive is applied by any of the methods described above to one side of the distal end of the dispensing tube (814A, 814B) below a tear notch (824) and weakened parting line (826) which serves to facilitate removal of the sealed end (832) of the dispensing tube in preparation for use. A score line (828) is provided at a point below the tear notch and in the center area of the pre-applied food grade PS cohesive. The transverse score line creates a complaint folding line to permit the user to fold dispensing tube as shown in FIG. 8B after an initial use and thereby seal it until the next use.

In an alternative embodiment illustrated FIG. 9 , a diaconal score and fold line (928) is provided in the dispensing tube (914), and the cohesive field (950A, 950B) lies above and below the line. Although the actual contact point of the food grade PS cohesive can be smaller, the closure at the point of the diagonal is more secure and easier to grip by the user when reopening.

In another alternative embodiment as illustrated in the series FIGS. 10A, 10B and 10C, the resealable closure is formed by depositing a predetermined quantity of food grade PS cohesive either during the film manufacturing process or in the process of producing the package on the package-forming machine as described above. The small field of adhesive is deposited on the interior of the dispensing channel (1020) between the inlet to the container (1012) and the weakened parting line (1026) as best shown in FIG. 10A. The type of commercially available adhesive selected is one in which the tack is responsive to manual pressure “F” applied b the user, either to the container portion (1012) of the package (1000) to move the flowable contents upward to force the distal end of the dispensing tube (1014) open and pass through the adhesive deposited. Conversely, when external pressure is applied to the dispensing tube at the location of the field of the resealable adhesive, the open end of the dispensing tube is again sealed and the package is secure against leaks. In both cases, the pressure is applied manually by the user to both seal and reopen the dispensing channel (1020).

The closure will require the adhesive to press the residual product out of the area of the deposit; the adhesive will then adhere to itself if a cohesive, or to the other side if it is a repositionable adhesive, through the residue of the product. Depending on the nature of the product, application of the adhesive can be to one or both sides of the interior of the dispensing channel proximate the end of the dispensing tube.

The choice of the type and selection of a specific commercially available adhesives for use with a given flowable product is within the skill of the art. The amount of, and the process(es) for its application will be determined in the context oil and subject to the technical specifications of the individual product contained in the dispensing package, all of which are within the skill in the art.

Integrated Mechanical Closures

In another embodiment of the present disclosure, the dispensing tube of a flexible dispensing package is provided with an integral manual closure by the addition of any one of commercially available types of polymeric zipper closures that are integrally bonded to the dispensing tube below the removable sealed portion and weakened tear line. These commercially available devices include the “press-to-close” and “slide-to-close” types of sealing devices. These closures are available in the form of strips on rolls that are known in the art as “zipper tapes”. The rolls of pre-manufactured closures are configured for installation at a fixed assembly station on a package-forming machine as the partially completed packages move past. Closure suppliers also sell, install and service their own custom machines for purchasers of their closure products.

Referring now to FIG. 11 , there is illustratively shown a flexible package (1110) with widened dispensing tube (1120) and an enlarged safety tab (1130) that is secured to the upper end of the dispensing tube by adhesive or heat bonding above the notches (1124) that identify the weakened tear line (1126). In the embodiment of FIG. 11 , the dispensing tube is provided with a resealable zipper closure (1150) positioned between the tear line (1126) and the lower end of the dispensing tube (1120). The closure can be of the press-to-close type, as shown, or the slide-to-close type.

The zipper closures are commercially available from, e.g., Presto Products Company of Appleton, Wis. 54912 under the brand name FRESH LOCK®, and from Zip-Pak Company, an Illinois Tool Works company of Carol Stream, Ill. 60188 under the brand name ZIP-PAK®. The closures are sold in bulk in the form of tapes that can be attached to a variety of polymer packaging films, e.g., by heat bonding for use in mass producing packaged products. Manufacturers of the closures also sell the production line equipment for the attachment to preformed packages, including horizontal and vertical form, fill and seal machines.

As ran be appreciated from the illustration of FIG. 11 , the widened dispensing tube (1120) is especially suited for discharging larger volumes of the flowable material in the container portion of the flexible stand-up package than be practical for smaller volume packages that are eminently suited for the distribution of individual portions of milk, juices, yogurt and other single serve consumer products. Larger packages, e.g., of a gallon or more can be used for other consumer products, such as kitty litter, sugar and the like, or commercial and industrial products in dry or liquid form, where the package contents are to be used over time and the purchaser wishes to securely reseal the package for storage until the next use.

It will be understood from the above disclosure of a variety of embodiments, that an improved highly flexible package with an integral dispensing tube results by providing laterally extending removable enlarged safety tab that avoids the potential hazard posed by the relatively much smaller separated sealed closure portion of the prior art. The benefits and advantages are especially apparent in the packaging of food products, where the smaller closure portion might be ingested by a small child, or even a pet if it were not properly disposed of. The enlarged safety tab also provides a number of additional benefits and advantages to the marketer for identifying and promoting products in this novel form of hi hl flexible thermoformed dispensing packages for flowable food products and other classes of commercial and industrial products.

While various exemplary embodiments of the invention have been described above and in the attached drawings, further modifications will be apparent to those or ordinary skill in the art from these examples and this description. The scope of the invention is to be determined with reference to the claims that follow. 

1. A highly flexible thermoformed dispensing package for a flowable material, the package produced from one or more heat-sealable flexible polymeric sheets to form a fluid-tight dispensing package and comprising: a. a thermoformed container portion that includes a recessed chamber having opposing side walls, top and base walls and bounded by a peripheral area, the chamber configured and arranged to receive the flowable material, b. an elongated dispensing tube integrally formed with the container portion and bounded by a contiguous peripheral area, the dispensing tube defining a dispensing channel dimensioned to pass the flowable material, the base of the dispensing tube channel being in fluid communication with the chamber, the opposing free end of the dispensing tube being formed with a sealed closure portion, the dispensing tube having a weakened transverse parting line proximate the sealed closure portion to facilitate the manual removal of the sealed closure portion to open the channel for dispensing the flowable material, and c. an enlarged safety tab extending from the sealed closure portion of the dispensing tube, the enlarged safety tab being integrally formed from the one or more heat-sealed polymeric sheets from which the dispensing package is formed and dimensioned and configured to avoid inadvertent ingestion by a human when the enlarged safety tab and sealed closure portion are separated from the dispensing tube.
 2. (canceled)
 3. (canceled)
 4. The dispensing package of claim 1 in which the dispensing tube is formed contiguously with an exterior sidewall of the container portion and the enlarged safety tab extends over the container portion and below the transverse weakened parting line proximate to, but separated from the dispensing tube.
 5. The dispensing package of claim 1 in which the dispensing tube extends from the container portion from a position that is inwardly displaced from the opposing side walls of the container portion and the enlarged safety tab extends from one or both of the opposing sides of the sealed closure portion and over the container portion.
 6. The dispensing package of claim 5 in which the opposing lateral edges of the enlarged safety tab lie on or within the vertical projection of the opposing side walls of the container portion.
 7. The dispensing package of claim 1 in which the configuration of the enlarged safety tab is rectangular, triangular, polygonal, round, oval or a combination of such configurations.
 8. The dispensing package of claim 1 in which the enlarged safety tab includes a transverse scored fold line and two or more spaced-apart fields of pressure sensitive adhesive dimensioned and configured to secure the EST when folded onto itself along the second fold line with the pressure sensitive adhesive fields in contact in position over the open end of the dispensing tube following removal of the enlarged safety tab from the dispensing tube to retain any remaining flowable material in the dispensing package after the sealed closure portion has been removed for dispensing.
 9. The dispensing package of claim 8 in which the fold line generally bisects the area defined by the enlarged safety tab.
 10. The dispensing package of claim 1 in which the enlarged safety tab is formed from two opposing heat-sealable polymeric sheets, where two of the edges of the enlarged safety tab are sealed along their periphery and a third edge is open to form a sleeve, the opening being dimensioned to receive the open end of the dispensing tube in close-fitting relation.
 11. The dispensing package of claim 10 in which the edge opposite the portion of the enlarged safety tab that is joined to the removable sealed closure portion is open.
 12. The dispensing package of claim 8 in which the opposing interior surfaces of the sleeve proximate its open end include fields of repositionable pressure sensitive adhesive for removably retaining the sleeve in position over the open end of the dispensing tube.
 13. (canceled)
 14. (canceled)
 15. (canceled)
 16. The dispensing package of claim 1 in which the enlarged safety tab comprises three or more superposed sheets and one of the sheets is formed from a rigid or semi-rigid material.
 17. (canceled)
 18. The dispensing package of claim 1 in which the enlarged safety tab comprises three superposed sheets and wherein one of the superposed sheets is separately removable from the enlarged safety tab following manual removal of a portion of the enlarge safety tab along one or more weakened parting lines.
 19. (canceled)
 20. The dispensing package of claim 1 in which the external surface of the dispensing tube includes a field of pressure sensitive adhesive positioned between the transverse weakened parting line and the container portion, the pressure sensitive adhesive being configured and dimensioned to engage in mating relation with a portion of the dispensing tube when the open end is folded down onto itself in the direction of the container portion.
 21. The dispensing package of claim 20 in which the field of pressure sensitive adhesive extends along the longitudinal axis of the dispensing tube.
 22. (canceled)
 23. The dispensing package of claim 1 in which the interior surface of the channel in the dispensing tube includes at least one field of pressure sensitive adhesive having characteristics that seal the channel against passage of the flowable material when the flowable material is subjected to the nominal force of gravity and that is releasable to open the channel for flow when the flowable material in the package is pressurized by application of a manual force to the exterior walls of the flexible container portion.
 24. A flexible thermoformed dispensing package for a flowable material, the package produced from one or more heat-sealable polymeric sheets to form a fluid-tight dispensing package and comprising: a. a thermoformed container portion that includes a recessed chamber having opposing side walls, top and base walls and bounded by a peripheral area, the chamber configured and arranged to receive the flowable material, b. an elongated dispensing tube integrally formed with the container portion and bounded by a contiguous peripheral area, the dispensing tube defining a dispensing channel dimensioned to pass the flowable material, the base of the dispensing tube channel being in fluid communication with the chamber, the opposing free end of the dispensing tube being formed with a sealed closure portion, the dispensing tube having a weakened transverse parting line proximate the sealed closure portion to facilitate the manual removal of the sealed closure portion to open the channel for dispensing of the flowable material, and c. an enlarged safety tab to extending from the sealed closure portion of the dispensing tube, the enlarged safety tab being integrally formed from the one or more heat-sealed polymeric sheets from which the dispensing package is formed and dimensioned and configured to avoid inadvertent ingestion by a human when the enlarged safety tab and sealed closure portion are separated from the dispensing tube.
 25. The dispensing package of claim 24 in which the enlarged safety tab comprises a separate article of manufacture that is securely joined to the sealed closure portion of the dispensing tube by adhesive or heat bonding.
 26. (canceled)
 27. The dispensing package of claim 24 in which the enlarged safety tab comprises a sleeve dimensioned and configured to receive at least one of a generally planar article or a three-dimensional article.
 28. The dispensing package of claim 24 in which the dispensing tube incorporates a polymeric zipper closure positioned proximate the sealed closure portion.
 29. (canceled) 